Specialized connection devices and method of use

ABSTRACT

An anchor bolt fastener assembly with specialized connection capabilities and features for attaching building components to concrete slabs, walls, ceilings, and/or structural surfaces. Compression force can be established and maintained over time using a compression washer in combination with a specialized fastener stud that is designed to exploit the compression washer benefits. Methods of using exemplary embodiments include installing the anchor bolt fastener assembly relatively flush with the surface of the concrete slurry by direct insertion in the slurry using a specialized threaded anchor bolt float. Once the slurry hardens, the anchor bolt and anchor bolt float embedded in the concrete slurry cooperate with the specialized fastener stud to secure the building component to the concrete.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/532,558 filed Jul. 14, 2017 so that the entire disclosure of theabove application is incorporated herein by reference.

FIELD

The subject disclosure generally relates to fasteners and anchoringsystems used to secure structures or other components to concrete and/orsimilar foundation support structures.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Various anchoring systems and methods are commonly used in theconstruction industry to secure and fasten buildings to concrete and/orsimilar foundation support structures. One of the most common methods isthe use of anchor bolts, which are embedded in concrete slurry beforethe concrete slurry is fully cured. Anchor bolts typically have athreaded portion and an unthreaded portion, which may be bent orL-shaped. During installation, the anchor bolts are embedded atorientations where the threaded portion of the anchor bolts protrudeabove the slurry surface. When the concrete has cured, constructionelements of a building are then attached to the threaded portion of theanchor bolts. For example, wall constructions such as wood framestructures may be attached to anchor bolts. Typically, the 2×4 or 2×6bottom plate of the wall is bolted to the anchor bolt, which typicallypasses through a hole in the bottom plate of the wall and is fastenedwith a nut and washer. As another example, structural beams may bebolted to anchor bolts.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

The present disclosure is directed to an improved anchor bolt fastenerassembly, which includes an anchor bolt that is capable of beinginstalled relatively flush with the concrete slurry so that it cancooperate with a fastener stud for securing a building to the concrete.The anchor bolt fastener assembly of the present disclosure includes ananchor bolt float that has a threaded bore at a first end of the anchorbolt float, an inner receiving chamber at a second end of the anchorbolt float, and an outer slurry contact surface disposed between thefirst and second ends. When the anchor bolt float is embedded in theconcrete slurry, the second end of the anchor bolt float is configuredto be generally oriented relatively flush with the surface of theconcrete slurry while the first end of the anchor bolt float isconfigured to be generally submerged deep below the surface of theconcrete slurry. This results in an improved anchor bolt fastenerassembly with a threaded flush float that is oriented relatively flushwith the grade of the slurry.

When the slurry is still wet after pouring, exemplary embodiments of theanchor bolt fastener assembly disclosed herein can be inserted into theslurry and positioned relatively flush with the surface grade of theslurry. This makes finishing the slurry easy, fast, and cost effectivebecause the anchor bolt fastener assembly does not extend above thesurface grade of the slurry. As a result, automatic surface finishingmachines can be used effectively.

Once the slurry is cured, construction walls and/or structural columnscan be positioned over the anchor bolt fastener assembly disclosedherein without the difficulty of lifting the construction walls and/orstructural columns over protruding threaded portions of the anchor boltsextending out of the concrete as in prior art designs. Mounting holes inthe construction walls and/or structural columns can simply be alignedwith the inner receiving chamber in the anchor bolt float and fastenedusing specialized fastener studs, which cooperate with the anchor boltto secure the structures to the hardened slurry. The specializedfastener studs can include, but are not limited to, bolt-like fastenerswith female ends with integrated compression washer features, bolt-likefasteners with female ends without integrated compression washerfeatures, and/or loose compression washers.

BRIEF DESCRIPTION OF DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

Other advantages of the present invention will be readily appreciated,as the same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a top plan view of an exemplary compression washer of ananchor bolt fastener assembly constructed in accordance with the subjectdisclosure;

FIG. 2 is a side elevation view of the exemplary compression washershown in FIG. 1;

FIG. 3 is a side section view of the exemplary compression washer shownin FIG. 1 taken along section line A-A in FIG. 1;

FIG. 4 is a top plan view of another exemplary compression washer of ananchor bolt fastener assembly constructed in accordance with the subjectdisclosure;

FIG. 5 is bottom plan view of the exemplary compression washer shown inFIG. 4;

FIG. 6 is a side elevation view of the exemplary compression washershown in FIG. 4;

FIG. 7 is a side section view of the exemplary compression washer shownin FIG. 4 taken along section line A-A in FIG. 4;

FIG. 8 is an enlarged partial right-side section view of a portion ofthe exemplary compression washer shown in circle B-B in FIG. 7;

FIG. 9 is an enlarged partial left-side section view of a portion of theexemplary compression washer shown in circle C-C in FIG. 7;

FIG. 10 is a side section view of an exemplary fastener stud of ananchor bolt fastener assembly constructed in accordance with the subjectdisclosure;

FIG. 11 is a side section view of the exemplary compression washer shownin FIG. 1 in a sub-assembly with the exemplary fastener stud shown inFIG. 10;

FIG. 12 is a side section view of an exemplary anchor bolt fastenerassembly constructed in accordance with the subject disclosure, wherethe exemplary anchor bolt fastener assembly is shown securing a typicalwood frame structure to a concrete slurry foundation; and

FIG. 13 is a side section view of another exemplary anchor bolt fastenerassembly constructed in accordance with the subject disclosure, wherethe exemplary anchor bolt fastener assembly is shown securing a typicalwood frame structure to a concrete slurry foundation.

DETAILED DESCRIPTION

Referring to the Figures, wherein like numerals indicate correspondingparts throughout the several views, an anchor bolt fastener assembly isillustrated.

Example embodiments will now be described more fully with reference tothe accompanying drawings. Example embodiments are provided so that thisdisclosure will be thorough, and will fully convey the scope to thosewho are skilled in the art. Numerous specific details are set forth suchas examples of specific components, devices, and methods, to provide athorough understanding of embodiments of the present disclosure. It willbe apparent to those skilled in the art that specific details need notbe employed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

Referring to FIGS. 1-3, a first exemplary embodiment of a compressionwasher 1 for an anchor bolt fastener assembly is illustrated. Thecompression washer 1 has an inside diameter 2, an outside diameter 3,and an overall thickness 4. The inside diameter 2 defines a center holeH in the compression washer 1. The compression washer 1 has a roundedprofile at the outside diameter 3. The underside of compression washer 1has an annular groove G positioned radially between the inside diameter2 and the outside diameter 3. The compression washer 1 has a reducedthickness at the annular groove G, which creates a first compressionsurface C1 with a radial width 9 and a second compression surface C2with a radial width 6. The first compression surface C1 is positionedradially between the outside diameter 3 and the annular groove G, whilethe second compression surface C2 is positioned radially between theinside diameter 2 and the annular groove G. The second compressionsurface C2 is inset or recessed in the compression washer 1 relative tothe first compression surface C1 by a recessed distance 12.

During assembly, the first compression surface C1 makes initial contactwith a bottom plate 32 of a wall construction (not shown) or similarstructural building component (see FIG. 12). As compressive fasteningforces increase, the compression washer 1 begins to flex such thatrecessed distance 12 is reduced. As compressive fastening forcesapproach maximum levels, the second compression surface C2 is broughtinto contact with the bottom plate 32 of the wall construction orsimilar structural building component.

Referring to FIGS. 4-9, a second exemplary embodiment of a compressionwasher 16 for an anchor bolt fastener assembly is illustrated. Thecompression washer 16 has an outside diameter 17, an inside diameter 18,and an overall thickness 19. The inside diameter 18 defines a centerhole H in the compression washer 16. The compression washer 16 hasbeveled outer edges 24 at the outside diameter 17. The underside ofcompression washer 16 has an annular groove G positioned radiallybetween the inside diameter 18 and the outside diameter 17. Thecompression washer 16 has a reduced thickness at the annular groove G,which creates a first compression surface C1 and a second compressionsurface C2. The first compression surface C1 is positioned radiallybetween the outside diameter 17 and the annular groove G, while thesecond compression surface C2 is positioned radially between the insidediameter 18 and the annular groove G. The second compression surface C2is inset or recessed in the compression washer 16 relative to the firstcompression surface C1 by a recessed distance 20.

The radii of outer edges 24 are greater than the radii of center edges26 and the radii of the center edges 26 are greater than the radii ofthe inner edges 25. The relationship of the radii of edges 24, 25, and26 is expressed by Equation I, below:Outer Radii>Center Radii>Inner Radii   Equation I

Referring to FIG. 10, a section view of an exemplary embodiment of aspecialized fastener stud 27 is illustrated with a first threaded end 31and a second threaded end 30. In some exemplary examples of thespecialized fastener stud 27, the first threaded end 31 may not have thesame thread size as the second threaded end 30. The fastener stud 27includes a shank 29 that is cylindrical in shape with a through-bore Bat the center. A flange-stop 28 extends radially outwardly from theshank 29 close to the second threaded end 30. The shank 29 can be asmuch as three fourths of the total length of the fastener stud 27between the flange-stop 28 and first threaded end 31.

An inspection hole 40 is provided in fastener stud 27 adjacent to thesecond threaded end 30. The inspection hole 40 provides a method ofvisual confirmation of proper thread engagement when an optionalthreaded component (not shown) is threaded into the second threaded end30 of the fastener stud 27. The inspection hole 40 also provides amethod of inserting a probe into the through-bore B for physicalconfirmation of proper thread engagement when the threaded component isfastened into the second threaded end 30. By way of example and withoutlimitation, the threaded component that is threaded into the secondthreaded end 30 of the fastener stud 27 may be a threaded fastener, suchas a bolt.

Referring to FIG. 11, a sub-assembly is shown where the specializedfastener stud 27 is assembled with the compression washer 1. To formthis sub-assembly, the shank 29 of the fastener stud 27 is insertedthrough the center hole H in the compression washer 1. The compressionwasher 1 is slid up the shank 29 until the compression washer 1 makescontact with the flange-stop 28 of the fastener stud 27. As shown inFIG. 12, the sub-assembly is further assembled with a wood bottom plate32 of a wall construction (not shown) and an anchor bolt float 35.

The anchor bolt float 35 includes a threaded bore F3 in a first end F4of the anchor bolt float 35, an inner receiving chamber F1 that is opento a second end F2 of the anchor bolt float 35, and an outer slurrycontact surface F5 disposed between the first and second ends F2, F4.When the anchor bolt float 35 is embedded in concrete slurry 33, thesecond end F2 is configured to be generally oriented relatively flushwith the top surface 34 (i.e., grade) of the concrete slurry 33, whilethe first end F4 is configured to be generally submerged deep below thesurface of the concrete slurry 33.

Anchor bolt 36 is embedded in the concrete slurry 33. The anchor bolt 36includes a threaded portion 37, which screws into the threaded bore F3in the anchor bolt float 35, and a tail portion D that has an L-shape.The threaded portion 37 of the anchor bolt 36 protrudes into the innerreceiving chamber F1 of the anchor bolt float 35, which receives thefirst threaded end 31 of the fastener stud 27. The threaded portion 37of the anchor bolt 36 screws into the first threaded end 31 of thefastener stud 27 completing a threaded connection. The wood bottom plate32 is secured to the top surface 34 of the concrete slurry 33 by thefastener stud 27 and the compression washer 1. It should be appreciatedthat in a different embodiment, compression washer 16 can be substitutedfor compression washer 1. It should also be appreciated that otherconstruction elements, such as a beam, could be substituted for the woodbottom plate 32 and that other orientations are possible where surface34 of the concrete 33 is vertical, at an angle, or is a bottom or sidesurface instead of a top surface.

Referring to FIG. 13, a sub-assembly is shown that includes a differentspecialized fastener stud 38 with an integral compression washer 39. Inaccordance with this design, the flange-stop 28 of fastener stud 27 andthe compression washer 1 are replaced by the integral compression washer39, which is part of fastener stud 38. The fastener stud 38 extendsthrough the wood bottom plate 32 of the wall construction (not shown)and is received by the inner receiving chamber F1 of the anchor boltfloat 35. The anchor bolt 36 is embedded in the concrete slurry 33 andthe wood bottom plate 32 is secured to the top surface 34 of theconcrete slurry 33 by the fastener stud 38, which is coupled to thethreaded portion 37 of the anchor bolt 36.

A construction connection method for attaching a building component 32to hardened concrete slurry 33 is also provided. The method furthercomprises the steps of: threading the anchor bolt 36 into the first endF4 of the anchor bolt float 35 and embedding the anchor bolt 36 and theanchor bolt float 35 in the concrete slurry 33 before the concreteslurry is cured such that the second end F2 of the anchor bolt float 35is flush with the top surface 34 of the concrete slurry 33. The methodfurther includes the steps of: sliding the compression washer 1 over theshank 29 of the fastener stud 27, placing the building component 32 overthe anchor bolt float 35, inserting the shank 29 of the fastener stud 27into a hole provided in the building component 32, inserting the firstthreaded end 31 of the fastener stud 27 into the inner receiving chamberF1 of the anchor bolt float 35, and threading the first threaded end 31of the fastener stud 27 to the threaded portion 37 of the anchor bolt36.

The method continues with the steps of: providing the compression washer1 with a first compression surface C1 and a second compression surfaceC2 and tightening the fastener stud 27 relative to the anchor bolt 36 toapply a compressive force to the compression washer 1 so that thecompression washer 1 flexes allowing the second compression surface C2to make contact with the building component 32. It should be understoodthat the term “building component” is simply used to refer to structuralcomponents or members used to build a structure and therefore, can be,but is not limited to, components used in buildings.

The method also comprises the steps of: inserting a threaded component(not shown) into the second threaded end 30 of the fastener stud 27,providing an inspection hole 40 in the fastener stud 27, and viewing thethreaded component through the inspection hole 40 to confirm that thethreaded component has been inserted to a proper threaded depth. Themethod may also optionally include the step of inserting a probe (notshown) through the inspection hole 40 to confirm proper threadedinsertion depth.

It should be appreciated that although the steps of the methods aredescribed and illustrated herein in a particular order, the steps may beperformed in a different order without departing from the scope of thesubject disclosure, except where the order of the steps is otherwisenoted. In the same vein, it should be appreciated that the methodsdescribed and illustrated herein may be performed without the inclusionof all the steps described above or with the addition of interveningsteps that have not been discussed, all without departing from the scopeof the subject disclosure.

Many modifications and variations of the present disclosure are possiblein light of the above teachings and may be practiced otherwise than asspecifically described while within the scope of the appended claims.These antecedent recitations should be interpreted to cover anycombination in which the inventive novelty exercises its utility.

What is claimed is:
 1. An anchor bolt fastener assembly for securing astructural building component to hardened concrete slurry, said anchorbolt fastener assembly comprising: a fastener stud comprising a shankand a through-bore with a first threaded end; a compression washerextending annularly about said shank of said fastener stud; an anchorbolt float configured to be imbedded in the concrete slurry, said anchorbolt float extending between a first end and a second end comprising aninspection hole that allows an installer to confirm proper insertionlength of a construction fastener inserted into said second threadedend; said first end of said anchor bolt float including a threaded bore;and said anchor bolt float comprising an inner receiving chamber that isopen to said second end of said anchor bolt float and is configured toreceive at least part of said fastener stud; and an anchor boltcomprising a tail portion configured to be embedded in the concreteslurry and a threaded portion that is threadably received in saidthreaded bore of said anchor bolt float such that at least part of saidthreaded portion of said anchor bolt extends into said inner receivingchamber of said anchor bolt float where said threaded portion of saidanchor bolt is threadably received in said first threaded end of saidfastener stud to couple said fastener stud to said anchor bolt.
 2. Theanchor bolt fastener assembly as set forth in claim 1, wherein saidfastener stud has a second threaded end.
 3. The anchor bolt fastenerassembly as set forth in claim 2, wherein said first threaded end andsaid second threaded end of said fastener stud have the same thread sizediameter.
 4. The anchor bolt fastener assembly as set forth in claim 2,wherein said first threaded end and said second threaded end of saidfastener stud have different thread size diameters.
 5. The anchor boltfastener assembly as set forth in claim 1, wherein said compressionwasher includes a center hole with an inside diameter, an outsidediameter, and an annular groove positioned radially between said insidediameter and said outside diameter.
 6. The anchor bolt fastener assemblyas set forth in claim 5, wherein said compression washer has a firstcompression surface that is positioned radially between said outsidediameter and said annular groove and a second compression surface thatis positioned radially between said inside diameter and said annulargroove.
 7. The anchor bolt fastener assembly as set forth in claim 6,wherein said compression washer has an outer pair of radii at saidoutside diameter, a center pair of radii between said first compressionsurface and said annular groove, and an inner pair of radii between saidsecond compression surface and said annular groove.
 8. The anchor boltfastener assembly as set forth in claim 7, wherein the relative size ofthe respective radii is expressed by the equation: outer radii>centerradii>inner radii.
 9. The anchor bolt fastener assembly as set forth inclaim 6, wherein said second compression surface is inset relative tosaid first compression surface by a recessed distance.
 10. The anchorbolt fastener assembly as set forth in claim 1, wherein said second endof said anchor bolt float is configured to be flush with a surface ofthe concrete slurry and wherein said fastener stud extends through ahole in the structural building component such that the structuralbuilding component is positioned between said second end of said anchorbolt float and said compression washer.
 11. The anchor bolt fastenerassembly as set forth in claim 10, wherein the structural buildingcomponent is one of a wood bottom plate of a wall construction or astructural beam.
 12. The anchor bolt fastener assembly as set forth inclaim 1, wherein said anchor bolt float includes an outer slurry contactsurface that extends from said first end of said anchor bolt float tosaid second end of said anchor bolt float that prevents the concreteslurry from entering said inner receiving chamber of said anchor boltfloat.
 13. The anchor bolt fastener assembly as set forth in claim 1,wherein said compression washer is a separate component from saidfastener stud and is retained by a flange-stop that extends radiallyoutwardly from said shank of said fastener stud.
 14. The anchor boltfastener assembly as set forth in claim 1, wherein said compressionwasher is an integral portion of said fastener stud.
 15. The anchor boltfastener assembly as set forth in claim 1, wherein said tail portion ofsaid anchor bolt has an L-shape.
 16. The anchor bolt fastener assemblyof claim 1, wherein said compression washer further comprises: a centerhole with an inside diameter, an outside diameter, and an annular groovepositioned radially between said inside diameter and said outsidediameter; a first compression surface that is positioned radiallybetween said outside diameter and said annular groove and a secondcompression surface that is positioned radially between said insidediameter and said annular groove; an outer pair of radii at said outsidediameter, a center pair of radii between said first compression surfaceand said annular groove, and an inner pair of radii between said secondcompression surface and said annular groove, wherein the relative sizeof the respective radii is expressed by the equation: outer radii>centerradii>inner radii and said second compression surface is inset relativeto said first compression surface by a recessed distance.